Design, fabrication, and hypervelocity impact testing of screen-printed flexible micrometeoroid and orbital debris impact sensors for long-duration spacecraft health monitoring

Micrometeoroid and orbital debris (MMOD) are a key risk for spacecraft damage that could compromise missions. Detecting and evaluating MMOD damage is therefore a crucial component in the health monitoring of spacecraft, especially for long duration, deep space expeditions. In this work, we developed a passive sensor system fabricated from conductive metal ink screen-printed on flexible Kapton, using roll-to-roll manufacturing suitable for low-cost fabrication of large areas of sensors, as a MMOD sensor for a spacecraft shield. The sensor is integrated into a low density, two-wall Whipple shield comprising of thin aluminum sheets sandwiching a polyimide foam. The shield with the sensors were tested with hypervelocity impacts at approximately 7 km/s using different particle diameters. Data collected from the sensors were successfully used to determine the impact size, impact location, and predict the impact energy of the damage.